Process for the production of ceramic articles



Patented Oct. 3, 1950 PROCESS FOR THE PRODUCTION OF CERAMIC ARTICLES Robert Le Grande Stone, Ligonier, Pa., assignor to the United States of America, as represented by the administrator,

Administration Civilian Production NoDrawing. Application May 31, 1946, Serial No. 673,484

3 Claims. 1

The invention described herein may be manufactured and used by or for the Government of the United States for governmental purposes without the payment to me of any royalty thereon.

weight of talc or other steatite mineral be employed.

Suitable alkylol amines for employment in this invention include the mono-di and triethanol,

This invention relates to a method of making 5 propanol and butanol amines as well as similar ceramic articles comprising or containing steatite alkylol amines havingfrom 2 to 6 carbon atoms minerals. in each alkyl residue. A preferred alkylol amine It is an object of this invention to produce for employment in this invention is triethanol ceramic compositions of great unfired strength. amine, since it is readily available, requires only Another object is to produce steatite ceramic l0 amoderate curing temperature, and yieldsacured compositions which can be out, drilled, tapped or unfired ceramic article when suitably combined, otherwise shaped at very high speeds. A further which often has a strength of from 2 to 3 times object is to produce unfired steatite compositions that of first grade concrete or even higher which can be cut or otherwise fashioned into ex strengths. Generally, the selected amine is inceedingly thin shapes with a, high degree of accorporated in an amount of not more than 14 curacy. Other objects will be apparent as the percent by weight in the ceramic composition, ensuing description proceeds. based on the total weight of the composition.

The foregoing and other objects are accom- Preferably, between 10 and 14 percent by weight plished in accordance with this invention wherein of triethanol amine or other selected alkylol unfired steatite ceramic articles are prepared by amine has been found to yield consistently high combining a steatite mineral with a gum and an quality cured articles in accordance with this alkylol amine. It has been found that cured but invention. unfired ceramic articles having a'strength oi the Suitable gums for incorporation with the steaorder of grade A Portland cement concrete can tite mineral and the alkylol amine in accordance readily be prepared by combining a major prowith, this invention include starch conversion portion of a steatite mineral withminor proporproducts, gum arabic, jungle gum, rosin, locust tions of suitable vegetable gums and triethanol bean gum, gum ghatti and similar natural and amine or other suitable alkylol amines and there synthetic gums or resinous substances. Gener after curing the suitably shaped article at a'temally, it is preferred to employ a naturally occurperature not higher than 450 degrees F. During ring vegetable gum of which gum ghatti is prethe curing process, whichis preferably carried ferred. Usually, the selected gum is incorporated out in an atmosphere saturated with the selected in an amount not higher than 10 percent by alkylol amine, the article develops a compressive weight based on the total composition, and preferstrength of between 2000 pounds per square inch ably the gum ghatti or other gum is employed in up to as high as 9000 pounds per square inch, an amount between 2 and 5 percent by weight. depending upon the particular steatite minerals In preparing the ceramic compositions of this employed, the particular gum employed, and the invention it. is generally desirable to comminute selected alkylol amine. Since grade A Portland the tale or other selected steatite body to a unicement concrete develops astrength of only about formly fine size of, for example, minus 50 mesh 3000 pounds per square inch, one can readily to minus 200 mesh or finer as determined by a visualize the strength developed by my ceramic compositions.

Suitable steatite minerals for employment in accordance with this invention include talc, chlorite, pyrophyllite, sheridanite and similar hydrous magnesium silicates generically known as steatites. Talc itself constitutes a preferred steatite mineral for employment in accordance with this invention and generally is employed in major proportions in the final ceramic composition. Usually, it' is preferred that at least percent by r additional minerals suitably comminuted may be incorporated in the steatite base body when it is desired to modify the properties of the final fired ceramic article. For example, substances such as .ball clay, flint, alumina, feldspars, and similar ceramic adjuncts can be incorporated and if desired can replace the whole or a major part of is incorporated in the ceramic mix. The Whole is thoroughly mixed together and the desired article shaped by extrusion under high pressure, molding, turning on a potters wheel or other similar method.

After forming the desired shaped article, it is then baked or cured at an elevated temperature not higher than 450 degrees F. to remove the water and promote the reaction between the gum and the alkylol amine with the ceramic base body.

Generally, a baking or curing temperature between 300 and 400 degrees F. will be found satisfactory and preferably the shaped article is cured at a temperature of about 350 degrees F. It is preferable to complete the curing or baking operation in an oven wherein the atmosphere can be saturated with triethanol amine or other suitable alkylol amine since it has been found that the surfaces of the article are fully cured by following this procedure.

After the curing operation has been completed,

the shaped article will be found to have an extremely high strength and toughness similar to or higher than first grade Portland cement concrete. For example, compressive strengths between 2000 and 9000 pounds per square inch can easily be attained by this invention.

The cured articles can be shaped to very precise dimensions or into intricate shapes such as employed in high frequency radio communication work by turning on a lathe, or other shaping devices. After curing and if desired shaping to close tolerances, the ceramic articles prepared in accordance with this invention can then be fired in the usual manner at elevated temperatures of say 2000 to 2400 degrees F. in order to 43 develop the full ceramic properties of the composition.

The following table shows in parts by weigh From the foregoing, it will be apparent that this invention has provided ceramic compositions of very great unfired strength. Unfired strengths in excess of 9000 pounds per square inch have been attained in accordance with this invention, which is approximately three times the compressive strength of first quality Portland cement concrete. Obviously, in the fashioning of complicated steatite bodies or other ceramic compositions, such an unfired strength permitting machining, drilling, tapping, and similar shaping operations to close dimensions, are highly advantageous. Perfect sections of washers and thin disks have been cut from cured steatite bodies prepared in accordance with this invention having uniform thicknesses of not over six mils.

While it is not intended to be bound by any theory of reaction, it is assumed that the terrific strengths developed by the bodies prepared in accordance with this invention may result from the production of some sort of an inorganicorganic complex not hitherto identified.

Various changes can be made in the detailed embodiments of this invention without departing from the broad spirit and scope thereof.

What is claimed is:

l. A process for the production of a ceramic article having an unfired strength of the order of grade A Portland cement concrete, which comprises incorporating a comminuted steatite mineral with minor proportions of water, a vegetable gum and triethanolamine, then shaping the desired article, and baking at a temperature between 300 and 400 degrees Fahrenheit in an atmosphere of triethanolamine.

2. The process of claim 1, employing gum ghatti as the vegetable gum.

3. The process of claim 1, employing between 10 and 14 percent triethanolamine, between 4 and 7 percent water and baking at a temperature of about 350 degrees Fahrenheit.

ROBERT LE GRANDE STONE.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS exemplary compositions prepared in accordance Number Name Dat with this invention and cured at a temperature 5 1,977,698 Scott Oct. 23, 1934 of about 350 degrees F.: 2,390,765 York et al Dec. 11, 1945 Table I comminuted talc 50. 0 50.0 85.0 100 85.0 Clay 100 25. 0 l5. 0 15. 0 Fluxes (e. g. Feldspar) 15.0 Flint, alumina, etc. 10.0 Comminuted serpentine 50. 0 100.0 Gum (c. g. Jungle gum, gum Ghatti) 2.0 to 5.0 2 0 to 5 O 2.0 to 5.0 2.0 to 5.0 2.0 to 5.0 3.0 Gum (e. g. Corn gum, tapioca gum) 2. 0 to 5. 0 3 0 Amino (e. g. 'lriethanolamine) 4.0 to 14.0 4.0 to 14.0 4.0 to 14 0 4.0 to 14.0 4 0 to 14.0 4.0 to 14.0 Water 14.0 to 4.0 14.0 to 4.0 14.0 to 4 0 14.0 to 4.0 14 0 to 4.0 18 0 14.0 to 4.0 18.0 Compressive strength, p. s. i 5, 000+ 4, 500+ 5, 0+ 7, 000+ 9, 000+ 2, 800 4, 100+ 2, 200 

1. A PROCESS FOR THE PRODUCTION OF A CERAMIC ARTICLE HAVING AN UNFIRED STRENGTH OF THE ORDER OF GRADE A PORTLAND CEMENT CONCRETE, WHICH COMPRISES INCORPORATING A COMMINUTED STEATITE MINERAL WITH MINOR PROPORTIONS OF WATER, A VEGETABLE GUM AND TRIETHANOLAMINE, THEN SHAPING THE DESIRED ARTICLE, AND BAKING AT A TEMPERATURE BETWEEN 300 AND 400 DEGREES FAHRENHEIT IN AN ATMOSPHERE OF TRIETHANOLAMINE. 